JP5315361B2 - Method for manufacturing light emitting device - Google Patents

Description

  The present invention is used for manufacturing an EL element having a structure in which an anode, a cathode, and a luminescent material from which EL (Electro Luminescence) is obtained, in particular, a self-emitting organic material (hereinafter referred to as an organic EL material) is sandwiched. The present invention relates to a film forming apparatus and a film forming method.

  The organic EL material includes all light-emitting organic materials that emit light (phosphorescence and / or fluorescence) via singlet excitation, triplet excitation, or both excitation.

  In recent years, a display device using an EL element as a self-luminous element using the EL phenomenon of an organic EL material (hereinafter referred to as an EL display device) has been developed. Since the EL display device is a self-luminous type, it does not require a backlight like a liquid crystal display device, and further has a wide viewing angle, and thus is promising as a display unit of a portable device used outdoors.

  There are two types of EL display devices, a passive type (simple matrix type) and an active type (active matrix type), both of which are actively developed. In particular, active matrix EL display devices are currently attracting attention. In addition, EL materials used as a light emitting layer of an EL element include an organic material and an inorganic material, and the organic material is further classified into a low molecular (monomer) organic EL material and a high molecular (polymer) organic EL material. . Although both are actively studied, low molecular organic EL materials are mainly formed by vapor deposition, and high polymer organic EL materials are mainly formed by coating.

  In order to fabricate an EL display device for color display, it is necessary to form EL materials having different colors for each pixel. However, EL materials are generally weak against water and oxygen and cannot be patterned by photolithography. Therefore, it is necessary to form a pattern simultaneously with the film formation.

  The most common method is a method in which a mask made of a metal plate or glass plate (hereinafter referred to as a shadow mask) provided with an opening is provided between a substrate on which a film is formed and an evaporation source. In this case, since the EL material vaporized from the evaporation source passes through only the opening and is selectively formed, it is possible to form a patterned EL layer simultaneously with the film formation.

  In the conventional vapor deposition apparatus, the EL material flying radially from one vapor deposition source is deposited on the substrate to form a thin film. Therefore, the arrangement of the substrate has been devised in consideration of the flight distance of the EL material. For example, a device has been devised in which all the distances from the vapor deposition source to the substrate are made equal by fixing the substrate to a conical substrate holder.

  However, in the case of adopting a multi-chamfering process for producing a plurality of panels on a large substrate, if the above-described method is used, the substrate holder becomes very large, resulting in an increase in size of the film forming apparatus main body. In addition, since the substrate is a flat plate even in the single-wafer method, the distance from the evaporation source differs in the plane of the substrate, and it is difficult to form a film with a uniform film thickness.

  Furthermore, when a large substrate is used, the vaporized EL material does not spread sufficiently unless the distance between the vapor deposition source and the shadow mask is increased, and it becomes difficult to form a thin film uniformly on the entire surface of the substrate. Ensuring this distance also helps to increase the size of the device.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a film forming apparatus capable of forming a thin film with high throughput and high uniformity of film thickness distribution. It is another object of the present invention to provide a film forming method using the film forming apparatus of the present invention.

  The present invention uses a vapor deposition cell having a longitudinal direction (a portion into which a material for a thin film to be deposited) or a plurality of vapor deposition cells is provided, and moves the vapor deposition source in a direction perpendicular to the longitudinal direction of the vapor deposition source. Thus, a thin film is formed. Note that “having a longitudinal direction” means that the shape is an elongated rectangle, an elongated ellipse, or a line. In the case of the present invention, it is preferable that the length in the longitudinal direction is longer than the length of one side of the substrate on which the film is formed, since the treatment can be performed collectively. Specifically, it is good that it is 300 mm to 1200 mm (typically 600 to 800 mm).

The positional relationship between the vapor deposition source and the substrate of the present invention is shown in FIG. In FIG. 1, FIG.
FIG. 1B is a cross-sectional view taken along line AA ′ of FIG. 1A, and FIG. 1C is a cross-sectional view taken along line BB ′ of FIG. 1A. In FIGS. 1A to 1C, common reference numerals are used.

  As shown in FIG. 1A, a shadow mask 102 is installed below the substrate 101, and a rectangular deposition source 104 in which a plurality of deposition cells 103 are arranged in a straight line is installed below the shadow mask 102. . Note that in this specification, a substrate includes a substrate and a thin film formed thereon. Further, the surface of the substrate refers to a substrate surface on which a thin film is formed.

  The length in the longitudinal direction of the vapor deposition source 104 is longer than the length of one side of the substrate 101, and a mechanism for moving the vapor deposition source 104 in the arrow direction (direction perpendicular to the longitudinal direction of the vapor deposition source 104) is provided. A thin film can be formed on the entire surface of the substrate by moving the vapor deposition source 104. If the length in the longitudinal direction is shorter than one side of the substrate, the thin film may be formed by repeating several scans. Further, the same thin film may be stacked several times by repeatedly moving the vapor deposition source 104.

  The thin film material evaporated in each vapor deposition cell 103 is scattered upward and deposited on the substrate 101 through an opening (not shown) provided in the shadow mask 102. Thus, a thin film is selectively formed on the substrate 101. At this time, the region where the thin film material scattered from the vapor deposition cell 103 is formed is overlapped with the region where the thin film material scattered from another adjacent vapor deposition cell is formed. By overlapping the regions to be formed with each other, the film is finally formed in a rectangular region.

  As described above, the present invention uses a vapor deposition source in which a plurality of vapor deposition cells are arranged, so that radiation from a line is used instead of radiation from a conventional point, and the film thickness uniformity can be greatly improved. . Furthermore, film formation can be performed with high throughput by moving a rectangular deposition source below the substrate surface.

  Furthermore, according to the present invention, it is not necessary to increase the distance between the vapor deposition source 104 and the shadow mask 102, and vapor deposition can be performed in a very close state. This is because a plurality of vapor deposition cells are provided side by side, so that the film can be formed simultaneously from the center to the end of the substrate even if the scattering distance of the thin film material is short. This effect is higher as the deposition cells 103 are arranged more closely.

  The distance between the vapor deposition source 104 and the shadow mask 102 is not particularly limited because it varies depending on the density at which the vapor deposition cells 103 are provided. However, if it is too close, it becomes difficult to form a film uniformly from the center to the end of the substrate, and if it is too far, it will not be different from the conventional vapor deposition by radiation. Therefore, when the distance between the vapor deposition cells 103 is a, the distance between the vapor deposition source 104 and the shadow mask 102 is desirably 2a to 100a (preferably 5a to 50a).

  The film forming apparatus of the present invention configured as described above uses a vapor deposition source to ensure the uniformity of the thin film thickness distribution in a rectangular, elliptical, or linear region, and then moves the vapor deposition source thereon. By doing so, a highly uniform thin film can be formed on the entire surface of the substrate. Moreover, since it is not vapor deposition from a point, the distance of a vapor deposition source and a board | substrate can be shortened, and the uniformity of a film thickness can be improved further.

  It is also effective to provide a means for generating plasma in the chamber in the film forming apparatus of the present invention. By performing the plasma treatment with oxygen gas or the plasma treatment with a gas containing fluorine, the thin film formed on the chamber wall can be removed and the inside of the chamber can be cleaned. As means for generating plasma, parallel plate electrodes may be provided in the chamber, and plasma may be generated therebetween.

  By using the film forming apparatus of the present invention, it is possible to form a thin film with high uniformity of film thickness distribution on the substrate surface with high throughput.

The figure which shows the structure of a vapor deposition source. The figure which shows the structure of a vapor deposition chamber. The figure which shows the structure of a vapor deposition chamber. The figure which shows the structure of the film-forming apparatus. The figure which shows the structure of the film-forming apparatus. The figure which shows the structure of the film-forming apparatus. The figure which shows the structure of the film-forming apparatus. The figure which shows the structure of the film-forming apparatus.

The structure of the vapor deposition chamber provided in the film forming apparatus of the present invention is shown in FIG. FIG. 2 (A)
Is a top view of the vapor deposition chamber, and FIG. 2B is a cross-sectional view. In addition, a common code | symbol shall be used for a common part. In this embodiment mode, an example of forming an EL (electroluminescence) film as a thin film is shown.

  In FIG. 2A, 201 is a chamber and 202 is a substrate transfer port, from which a substrate is transferred into the chamber 201. The transferred substrate 203 is placed on the substrate holder 204 and transferred to the film forming unit 206 by the transfer rail 205 as indicated by an arrow 205.

  When the substrate 203 is transferred to the film forming unit 206, the shadow mask 208 fixed to the mask holder 207 approaches the substrate 203. In this embodiment, a metal plate is used as the material for the shadow mask 208. ((FIG. 2B)) In this embodiment, the opening 209 is formed in a rectangular, elliptical, or linear shape in the shadow mask 208. Of course, the shape of the opening is not limited to this. Alternatively, it may be formed in a matrix shape or a mesh shape.

  At this time, in this embodiment, as shown in FIG. 2B, the electromagnet 210 is close to the substrate 203. When a magnetic field is formed by the electromagnet 210, the shadow mask 208 is drawn toward the substrate 203 and held at a predetermined interval. This interval is ensured by a plurality of protrusions 301 provided on the shadow mask 208 as shown in FIG.

  Such a structure is particularly effective when the substrate 203 is a large substrate exceeding 300 mm. When the substrate 203 is increased in size, deflection occurs due to the weight of the substrate. However, if the shadow mask 208 is pulled toward the substrate 203 by the electromagnet 210, the substrate 203 is also pulled toward the electromagnet 210, and the deflection can be eliminated. However, as shown in FIG. 4, it is preferable that the electromagnet 210 is also provided with a protrusion 401 to ensure a space between the substrate 203 and the electromagnet 210.

  When the space between the substrate 203 and the shadow mask 208 is secured in this way, the vapor deposition source 212 provided with the vapor deposition cell 211 having the longitudinal direction is moved in the direction of the arrow 213. During the movement, the EL material provided in the vapor deposition cell is vaporized by heating the vapor deposition cell and is scattered into the chamber of the film formation unit 206. However, in the case of the present invention, since the distance between the vapor deposition source 212 and the substrate 203 can be made very short, the EL to the drive unit (the portion that drives the vapor deposition source, the substrate holder or the mask holder) in the chamber. Material adhesion can be minimized.

  The deposition source 212 is scanned from one end of the substrate 203 to the other end. In this embodiment, as shown in FIG. 2A, since the length of the evaporation source 212 in the longitudinal direction is sufficiently long, the entire surface of the substrate 203 can be moved by one scan.

  When a red, green, or blue EL material (here, red) is formed as described above, the magnetic field of the electromagnet 210 is turned off, the mask holder 207 is lowered, and the distance between the shadow mask 208 and the substrate 203 is increased. Then, the substrate holder 204 is shifted by one pixel, the mask holder 207 is raised again, and the shadow mask 208 and the substrate 203 are brought closer to each other. Further, a magnetic field is formed by the electromagnet 210 to eliminate the deflection of the shadow mask 208 and the substrate 203. Thereafter, the deposition cell is switched to form a red, green or blue EL material (here, green) again.

  Here, the substrate holder 204 is shifted by one pixel, but the mask holder 204 may be shifted by one pixel.

  When all the red, green, and blue EL materials are formed by repeating such processes, the substrate 203 is finally transferred toward the substrate transfer port 202 and taken out from the chamber 201 by a robot arm (not shown). This completes the formation of the EL film using the present invention.

  The film forming apparatus of the present invention will be described with reference to FIG. In FIG. 5, reference numeral 501 denotes a transfer chamber. The transfer chamber 501 is provided with a transfer mechanism 502, and the substrate 503 is transferred. The transfer chamber 501 is in a reduced pressure atmosphere and is connected to each processing chamber by a gate. The transfer of the substrate to each processing chamber is performed by the transfer mechanism 502 when the gate is opened. In order to decompress the transfer chamber 501, an exhaust pump such as an oil rotary pump, a mechanical booster pump, a turbo molecular pump, or a cryopump can be used, but a cryopump effective for removing moisture is preferable.

  Hereinafter, each processing chamber will be described. Since the transfer chamber 501 has a reduced pressure atmosphere, all the processing chambers directly connected to the transfer chamber 501 are provided with an exhaust pump (not shown). As the exhaust pump, the above-described oil rotary pump, mechanical booster pump, turbo molecular pump, or cryopump is used.

First, reference numeral 504 denotes a load chamber for setting (installing) a substrate, which also serves as an unload chamber. The load chamber 504 is connected to the transfer chamber 501 by a gate 500a, and a carrier (not shown) on which a substrate 503 is set is disposed. It should be noted that the load chamber 504 may be distinguished for substrate loading and substrate unloading.
The load chamber 504 includes the above-described exhaust pump and a purge line for introducing high-purity nitrogen gas or rare gas.

  Note that in this embodiment, as the substrate 503, a substrate in which up to a transparent conductive film to be an anode of an EL element is formed is used. In this embodiment, the substrate 503 is set on the carrier with the deposition surface facing downward. This is for facilitating the face-down method (also referred to as a deposit-up method) when a film is formed by an evaporation method later. The face-down method refers to a method in which a film is formed with the deposition surface of the substrate facing down. According to this method, adhesion of dust and the like can be suppressed.

  Reference numeral 505 denotes a processing chamber (hereinafter referred to as a pretreatment chamber) for treating the surface of the anode or cathode (anode in this embodiment) of the EL element. The pretreatment chamber 505 is a transfer chamber by a gate 500b. 501 is connected. The pretreatment chamber can be variously changed depending on the manufacturing process of the EL element. In this embodiment, the surface of the anode made of the transparent conductive film can be heated at 100 to 120 ° C. while irradiating ultraviolet light in oxygen. . Such pretreatment is effective when the anode surface of the EL element is treated.

  Next, reference numeral 506 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method and is referred to as a vapor deposition chamber (A). The deposition chamber (A) 506 is connected to the transfer chamber 501 through the gate 500c. In this embodiment, a vapor deposition chamber having the structure shown in FIG.

  In this embodiment, in the film forming portion 507 in the vapor deposition chamber (A) 506, a hole injection layer is first formed on the entire substrate surface, then a light emitting layer that develops red color, and then light emission that produces green color. Then, a light emitting layer that develops a blue color is formed. Note that any material may be used for the hole injection layer, the red light emitting layer, the green light emitting layer, and the blue light emitting layer.

  The vapor deposition chamber (A) 506 is configured to be switchable in accordance with the type of organic material for forming a vapor deposition source. That is, the preliminary chamber 508 storing a plurality of types of vapor deposition sources is connected to the vapor deposition chamber (A) 506, and the vapor deposition sources can be switched by an internal transfer mechanism. Therefore, whenever the organic EL material to form into a film changes, a vapor deposition source will also be switched. The shadow mask is moved by one pixel each time the organic EL material for forming the same mask changes.

  Note that the description of FIG. 2 may be referred to for the film formation process in the vapor deposition chamber (A) 506.

Next, reference numeral 509 denotes a vapor deposition chamber for depositing a conductive film (a metal film serving as a cathode in this embodiment) that becomes an anode or a cathode of an EL element by a vapor deposition method, and is called a vapor deposition chamber (B). The vapor deposition chamber (B) 509 is connected to the transfer chamber 501 through the gate 500d.
In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (B) 509. In this embodiment, an Al—Li alloy film (alloy film of aluminum and lithium) is used as a conductive film to be a cathode of an EL element in the film forming portion 510 in the vapor deposition chamber (B) 509.
Is deposited.

  Note that it is possible to co-evaporate an element belonging to Group 1 or Group 2 of the periodic table and aluminum. Co-evaporation refers to an evaporation method in which an evaporation cell is heated at the same time and different substances are mixed in a film formation stage.

  Next, reference numeral 511 denotes a sealing chamber (also referred to as a sealing chamber or a glove box), which is connected to the load chamber 504 through a gate 500e. In the sealing chamber 511, a process for finally sealing the EL element in the sealed space is performed. This treatment is a treatment for protecting the formed EL element from oxygen and moisture, and means such as mechanical sealing with a sealing material or sealing with a thermosetting resin or an ultraviolet light curable resin is used.

  As the sealing material, glass, ceramics, plastic, or metal can be used, but when light is emitted to the sealing material side, it must be translucent. The sealing material and the substrate on which the EL element is formed are bonded together using a thermosetting resin or an ultraviolet light curable resin, and the resin is cured by heat treatment or ultraviolet light irradiation treatment to form a sealed space. It is also effective to provide a hygroscopic material typified by barium oxide in this sealed space.

  In addition, the space between the sealing material and the substrate on which the EL element is formed can be filled with a thermosetting resin or an ultraviolet light curable resin. In this case, it is effective to add a moisture absorbing material typified by barium oxide in the thermosetting resin or the ultraviolet light curable resin.

  In the film forming apparatus shown in FIG. 5, a mechanism (hereinafter referred to as an ultraviolet light irradiation mechanism) 512 for irradiating ultraviolet light is provided in the sealing chamber 511, and the ultraviolet light irradiation mechanism 512 emits the light. An ultraviolet light curable resin is cured by ultraviolet light. Further, the inside of the sealing chamber 511 can be decompressed by attaching an exhaust pump. In the case where the sealing step is mechanically performed by robot operation, mixing of oxygen and moisture can be prevented by performing it under reduced pressure. Conversely, the inside of the sealing chamber 511 can be pressurized. In this case, the pressure is increased while purging with high-purity nitrogen gas or rare gas to prevent oxygen or the like from entering from the outside air.

  Next, a delivery chamber (pass box) 513 is connected to the sealing chamber 511. A delivery mechanism (B) 514 is provided in the delivery chamber 513, and the substrate in which the EL element is sealed in the sealing chamber 511 is delivered to the delivery chamber 513. The delivery chamber 513 can also be decompressed by attaching an exhaust pump. The delivery chamber 513 is a facility for preventing the sealing chamber 511 from being directly exposed to the outside air, from which the substrate is taken out.

  As described above, by using the film formation apparatus illustrated in FIG. 5, it is not necessary to expose to the outside air until the EL element is completely enclosed in a sealed space, and thus a highly reliable EL display device can be manufactured. Become.

The film forming apparatus of the present invention is a multi-chamber method (also called a cluster tool method).
The case will be described with reference to FIG. In FIG. 6, reference numeral 601 denotes a transfer chamber. The transfer chamber 601 is provided with a transfer mechanism (A) 602, and the substrate 603 is transferred. The transfer chamber 601 is in a reduced-pressure atmosphere, and is connected to each processing chamber by a gate. The transfer of the substrate to each processing chamber is performed by the transfer mechanism (A) 602 when the gate is opened. In order to decompress the transfer chamber 601, an exhaust pump such as an oil rotary pump, a mechanical booster pump, a turbo molecular pump, or a cryopump can be used, but a cryopump effective for removing moisture is preferable.

  Hereinafter, each processing chamber will be described. Since the transfer chamber 601 is in a reduced pressure atmosphere, all the processing chambers directly connected to the transfer chamber 601 are provided with an exhaust pump (not shown). As the exhaust pump, the above-described oil rotary pump, mechanical booster pump, turbo molecular pump, or cryopump is used.

  First, reference numeral 604 denotes a load chamber for substrate setting (installation), which is also called a load lock chamber. The load chamber 604 is connected to the transfer chamber 601 by a gate 600a, and a carrier (not shown) on which a substrate 603 is set is disposed. It should be noted that the load chamber 604 may be distinguished for substrate loading and unloading. The load chamber 604 includes the above-described exhaust pump and a purge line for introducing high-purity nitrogen gas or rare gas.

  Next, reference numeral 605 denotes a pretreatment chamber for treating the surface of the anode or cathode (anode in this embodiment) of the EL element, and the pretreatment chamber 605 is connected to the transfer chamber 601 by a gate 600b. The pretreatment chamber can be variously changed depending on the manufacturing process of the EL element. In this embodiment, the surface of the anode made of the transparent conductive film can be heated at 100 to 120 ° C. while irradiating ultraviolet light in oxygen. . Such pretreatment is effective when the anode surface of the EL element is treated.

  Next, reference numeral 606 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method and is referred to as a vapor deposition chamber (A). The vapor deposition chamber (A) 606 is connected to the transfer chamber 601 through a gate 600c. In this embodiment, a vapor deposition chamber having the structure shown in FIG.

  In this embodiment, the hole injection layer and the light emitting layer that develops red color are formed in the film formation portion 607 in the vapor deposition chamber (A) 606. Therefore, two types of vapor deposition sources and shadow masks are provided corresponding to the hole injection layer and the organic material to be the light emitting layer that develops red color, and can be switched. A known material may be used for the hole injection layer and the light emitting layer that emits red color.

  Next, reference numeral 608 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method, and is referred to as a vapor deposition chamber (B). The deposition chamber (B) 608 is connected to the transfer chamber 601 through a gate 600d. In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (B) 608. In this embodiment, a green light emitting layer is formed in the film formation portion 609 in the vapor deposition chamber (B) 608. A known material may be used for the light emitting layer that emits green light.

  Next, reference numeral 610 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method, and is referred to as a vapor deposition chamber (C). The deposition chamber (C) 610 is connected to the transfer chamber 601 through the gate 600e. In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (C) 610. In this embodiment, a light emitting layer that develops blue color is formed in the film forming portion 611 in the vapor deposition chamber (C) 610. A known material may be used for the light emitting layer that develops blue color.

Next, reference numeral 612 denotes a vapor deposition chamber for depositing a conductive film (a metal film serving as a cathode in this embodiment) that becomes an anode or a cathode of an EL element by a vapor deposition method, and is referred to as a vapor deposition chamber (D). The deposition chamber (D) 612 is connected to the transfer chamber 601 through a gate 600f.
In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (D) 612. In this embodiment, an Al—Li alloy film (alloy film of aluminum and lithium) is used as a conductive film to be a cathode of the EL element in the film forming portion 613 in the vapor deposition chamber (D) 612.
Is deposited. Note that it is possible to co-evaporate an element belonging to Group 1 or Group 2 of the periodic table and aluminum.

  Next, reference numeral 614 denotes a sealing chamber, which is connected to the load chamber 604 through a gate 600g. The description of the sealing chamber 614 may refer to the first embodiment. Further, as in the first embodiment, an ultraviolet light irradiation mechanism 615 is provided inside the sealing chamber 614. Further, a delivery chamber 616 is connected to the sealing chamber 615. A delivery mechanism (B) 617 is provided in the delivery chamber 616, and the substrate in which the EL element is completely sealed in the sealing chamber 614 is delivered to the delivery chamber 616. The description of the delivery room 616 may also refer to the first embodiment.

  As described above, by using the film formation apparatus illustrated in FIG. 6, it is not necessary to expose to the outside air until the EL element is completely enclosed in a sealed space, and thus a highly reliable EL display device can be manufactured. Become.

  The case where the film forming apparatus of the present invention is an in-line method will be described with reference to FIG. In FIG. 7, reference numeral 701 denotes a load chamber from which the substrate is transferred. The load chamber 701 is provided with an exhaust system 700a, and the exhaust system 700a includes a first valve 71, a turbo molecular pump 72, a second valve 73, and a rotary pump (oil rotary pump) 74.

  The first valve 71 is a main valve, which may double as a conductance valve or a butterfly valve. The second valve 73 is a fore valve. First, the second valve 73 is opened, the load chamber 701 is roughly decompressed by the rotary pump 74, and then the first valve 71 is opened and the turbo molecular pump 72 is decompressed to a high vacuum. Although a mechanical booster pump or a cryopump can be used instead of the turbo molecular pump, the cryopump is particularly effective for removing moisture.

  Reference numeral 702 denotes a pretreatment chamber for treating the surface of the anode or cathode (anode in this embodiment) of the EL element, and the pretreatment chamber 702 includes an exhaust system 700b. The load chamber 701 is hermetically shut off by a gate (not shown). The pretreatment chamber 702 can be variously changed depending on the manufacturing process of the EL element. In this embodiment, the surface of the anode made of the transparent conductive film can be heated at 100 to 120 ° C. while irradiating ultraviolet light in oxygen. To do.

  Next, reference numeral 703 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method and is referred to as a vapor deposition chamber (A). The vapor deposition chamber (A) 703 includes an exhaust system 700c. The pretreatment chamber 702 is hermetically shut off by a gate (not shown). In this embodiment, a vapor deposition chamber having the structure shown in FIG.

  The substrate 704 transferred to the vapor deposition chamber (A) 703 and the vapor deposition source 705 provided in the vapor deposition chamber (A) 703 each move in the direction of the arrow, and film formation is performed. Note that the detailed operation of the vapor deposition chamber (A) 703 may be referred to the description of FIG. In this embodiment, a hole injection layer is formed in the vapor deposition chamber (A) 703. A known material may be used for the hole injection layer.

  Next, reference numeral 706 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method and is referred to as a vapor deposition chamber (B). The vapor deposition chamber (B) 706 includes an exhaust system 700d. Further, the deposition chamber (A) 703 is hermetically shut off by a gate (not shown). In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (B) 706. Therefore, the detailed operation of the vapor deposition chamber (B) 706 may be referred to the description of FIG. In this embodiment, a light emitting layer that develops red color is formed in the vapor deposition chamber (B) 706. A known material may be used for the light emitting layer that develops red color.

  Next, reference numeral 707 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method, and is referred to as a vapor deposition chamber (C). The vapor deposition chamber (C) 707 includes an exhaust system 700e. Further, the deposition chamber (B) 706 is hermetically sealed by a gate (not shown). In this embodiment, a vapor deposition chamber having the structure shown in FIG. Accordingly, the detailed operation of the vapor deposition chamber (C) 707 may be referred to the description of FIG. In this embodiment, a light-emitting layer that emits green light is formed in the vapor deposition chamber (C) 707. A known material may be used for the light emitting layer that develops a green color.

  Next, reference numeral 708 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method, and is referred to as a vapor deposition chamber (D). The vapor deposition chamber (D) 708 includes an exhaust system 700f. Further, the deposition chamber (C) 707 is hermetically shut off by a gate (not shown). In this embodiment, a vapor deposition chamber having the structure shown in FIG. 2 is provided as the vapor deposition chamber (D) 708. Accordingly, the detailed operation of the vapor deposition chamber (D) 708 may be referred to the description of FIG. In this embodiment, a light-emitting layer that develops blue color is formed in the vapor deposition chamber (D) 708. A known material may be used for the light emitting layer that develops a blue color.

Next, reference numeral 709 denotes a vapor deposition chamber for depositing a conductive film (a metal film serving as a cathode in this embodiment) that serves as an anode or a cathode of an EL element by a vapor deposition method, and is referred to as a vapor deposition chamber (E). The vapor deposition chamber (E) 709 includes an exhaust system 700 g. Further, the deposition chamber (D) 708 is hermetically shut off by a gate (not shown). In this embodiment, the deposition chamber (E)
709 is provided with a vapor deposition chamber having the structure shown in FIG. Therefore, the detailed operation of the vapor deposition chamber (E) 709 may be referred to the description of FIG.

  In this embodiment, in the vapor deposition chamber (E) 709, an Al—Li alloy film (an alloy film of aluminum and lithium) is formed as a conductive film that becomes a cathode of the EL element. Note that it is possible to co-evaporate an element belonging to Group 1 or Group 2 of the periodic table and aluminum.

  Next, reference numeral 710 denotes a sealing chamber, which includes an exhaust system 700h. The deposition chamber (E) 709 is hermetically shut off by a gate (not shown). The description of the sealing chamber 710 may refer to the first embodiment. Further, as in the first embodiment, an ultraviolet light irradiation mechanism (not shown) is provided inside the sealing chamber 710.

  Finally, reference numeral 711 denotes an unload chamber, which is provided with an exhaust system 700i. The substrate on which the EL element is formed is taken out from here.

  As described above, by using the film formation apparatus illustrated in FIG. 7, it is not necessary to expose to the outside air until the EL element is completely enclosed in a sealed space, so that a highly reliable EL display device can be manufactured. Become. In addition, an EL display device can be manufactured with high throughput by an inline method.

  A case where the film forming apparatus of the present invention is an in-line method will be described with reference to FIG. In FIG. 8, reference numeral 801 denotes a load chamber from which the substrate is transferred. The load chamber 801 is provided with an exhaust system 800a, and the exhaust system 800a includes a first valve 81, a turbo molecular pump 82, a second valve 83, and a rotary pump (oil rotary pump) 84.

  Reference numeral 802 denotes a pretreatment chamber for treating the surface of the anode or cathode (an anode in this embodiment) of the EL element, and the pretreatment chamber 802 includes an exhaust system 800b. The load chamber 801 is hermetically shut off by a gate (not shown). The pretreatment chamber 802 can be variously changed depending on the manufacturing process of the EL element. In this embodiment, the surface of the anode made of the transparent conductive film can be heated at 100 to 120 ° C. while being irradiated with ultraviolet light in oxygen. To do.

  Next, reference numeral 803 denotes a vapor deposition chamber for depositing an organic EL material by a vapor deposition method, and includes an exhaust system 800c. The pretreatment chamber 802 is hermetically sealed with a gate (not shown). In this embodiment, a vapor deposition chamber having the structure shown in FIG. The substrate 804 transferred to the vapor deposition chamber 803 and the vapor deposition source 805 provided in the vapor deposition chamber 803 each move in the direction of the arrow, and film formation is performed.

  Note that in this embodiment, a film is formed in the vapor deposition chamber 803 to form a hole injection layer, a light emitting layer that develops red color, a light emitting layer that develops green color, a light emitting layer that develops blue color, and a conductive film that becomes a cathode. It is preferable to switch the vapor deposition source 803 or the shadow mask (not shown) every time. In this embodiment, a preliminary chamber 806 is connected to the vapor deposition chamber 803, and a vapor deposition source or a shadow mask is stored in the preliminary chamber 806, and is switched as appropriate.

  Next, reference numeral 807 denotes a sealing chamber, which includes an exhaust system 800d. Further, the deposition chamber 803 is hermetically shut off by a gate (not shown). For the description of the sealing chamber 807, Embodiment 1 may be referred to. Further, as in the first embodiment, an ultraviolet light irradiation mechanism (not shown) is provided inside the sealing chamber 807.

  Finally, reference numeral 808 denotes an unload chamber, which is provided with an exhaust system 800e. The substrate on which the EL element is formed is taken out from here.

As described above, by using the film formation apparatus illustrated in FIG. 8, it is not necessary to expose to the outside air until the EL element is completely enclosed in a sealed space; thus, a highly reliable light-emitting device (EL display device) is manufactured. It becomes possible. In addition, an EL display device can be manufactured with high throughput by an inline method.

Claims (16)

A method for producing a light-emitting device using an in-line type vapor deposition apparatus having a plurality of vapor deposition cells arranged in a line, a vapor deposition source having a longitudinal direction, and a vapor deposition chamber,
Transport the substrate to the deposition chamber;
Vaporizing the thin film material from the deposition source;
A thin film is formed on the substrate by moving the position of the vapor deposition source with respect to the substrate in a direction perpendicular to the longitudinal direction of the vapor deposition source while the thin film material is vaporized. A method for manufacturing a light-emitting device. In claim 1,
A method for manufacturing a light-emitting device, wherein the thin film material includes a light-emitting material. In claim 1,
A method for manufacturing a light-emitting device, wherein the thin film material is an organic material. In any one of Claims 1 thru | or 3,
The length of the longitudinal direction in the said vapor deposition source is longer than the length of the one side of the said board | substrate, The manufacturing method of the light-emitting device characterized by the above-mentioned. An in-line type vapor deposition apparatus having a plurality of vapor deposition cells arranged in a line and having first and second vapor deposition sources having a longitudinal direction, a vapor deposition chamber, and a preliminary chamber connected to the vapor deposition chamber is used. A method for manufacturing a light emitting device,
Installing the first vapor deposition source in the vapor deposition chamber;
Storing the second vapor deposition source in the preliminary chamber;
Transport the substrate to the deposition chamber;
Vaporizing a first thin film material from the first deposition source;
While the first thin film material is vaporized, the position of the first vapor deposition source with respect to the substrate is moved in a direction perpendicular to the longitudinal direction of the first vapor deposition source to thereby change the first thin film material onto the substrate. 1 is deposited, and then the second deposition source is transported from the preliminary chamber to the deposition chamber,
Vaporizing a second thin film material from the second deposition source;
While the second thin film material is vaporized, the position of the second vapor deposition source with respect to the substrate is moved in a direction perpendicular to the longitudinal direction of the second vapor deposition source, thereby A method for manufacturing a light-emitting device, comprising forming a second thin film over a substrate. In claim 5,
A method for manufacturing a light-emitting device, wherein at least one of the first and second thin film materials includes a light-emitting material. In claim 5,
A method for manufacturing a light-emitting device, wherein at least one of the first and second thin film materials is an organic material. In any one of Claims 5 thru | or 7,
The length of the longitudinal direction in each of the first vapor deposition source and the second vapor deposition source is longer than the length of one side of the substrate. In any one of claims 1 to 8,
Fabricating a light-emitting device, wherein the substrate is disposed between a shadow mask and a magnet, the shadow mask is attracted toward the substrate by the magnet, and a thin film is formed on the substrate through the shadow mask. Method. In claim 9,
The method of manufacturing a light emitting device, wherein the shadow mask has a rectangular or elliptical opening, and the longitudinal direction of the opening is positioned perpendicular to the longitudinal direction of the vapor deposition source. In claim 9 or 10,
The method for manufacturing a light-emitting device, wherein the shadow mask has a protrusion. In any one of claims 9 to 11,
The method for manufacturing a light-emitting device, wherein the magnet has a protrusion. In any one of claims 1 to 12,
A method for manufacturing a light-emitting device, wherein a transfer rail is used when the substrate is transferred to a vapor deposition chamber.   14. The method for manufacturing a light-emitting device according to claim 1, wherein the deposition chamber is cleaned after a thin film is formed over the substrate. In claim 14,
A method for manufacturing a light-emitting device, wherein the deposition chamber is cleaned with plasma. In any one of claims 1 to 15,
A method for manufacturing a light-emitting device, wherein the light-emitting device is an active matrix EL display device.

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